Smart Sensors. RFID Tags. Augmented Reality. 3D Printing.
It’s not sci-fi anymore; it’s where rigging is headed. Additive manufacturing isn’t just for prototypes, but not everything belongs on a printer bed. This post breaks down how 3D printing is evolving in rigging, what’s viable now, and what’s still a work in progress.
At E-Rigging, we’ve seen firsthand how innovation pushes the envelope, and we're equally aware that not every advancement is ready from jump. Hardware that can be batch tested and validated within existing standards is where we see real promise, especially for users with niche lifting needs.
From Prototypes to Potential: A Quick History of 3D Printing
Let’s start from the beginning. 3D printing, or additive manufacturing (AM), isn't new. Originally used for rapid prototyping in aerospace and medical fields, the technology builds objects layer-by-layer using digital CAD models. Unlike subtractive manufacturing (where you carve material away from a solid block) additive manufacturing forms complex solid objects seemingly out of thin air while also reducing waste.
Until recently, 3D printing was mostly confined to plastic mockups or metal parts that weren’t subject to real-world stress. But in the last decade, sectors like oil and gas, defense, and marine engineering have started to experiment with load-bearing components. Standards bodies like ASME and the American Petroleum Institute (API) are stepping in to create frameworks for qualifying 3D printed parts in operational environments.
Rigging Hardware Gets the Additive Treatment
Of all the gear in your kit, smaller components—hooks, shackles, clevises—are the first real candidates for 3D printing. Why?
They’re compact.
They’re easy to repeatedly produce.
They’re easy to batch test.
In addition, they don’t require the same multi-directional strength that larger rigging structures do. Because additive manufacturing isn’t limited by traditional machining constraints, it enables the design of highly specific geometries, such as offset hooks or specialized couplers, for lifts where conventional hardware won’t work.
These components are typically produced using metal additive processes like direct metal laser sintering (DMLS) or electron beam melting—techniques capable of printing in high-strength alloys. That means the end component isn’t just theoretical; it can be validated using industry-standard quality controls. Printed metal rigging gear can undergo finite element analysis, non-destructive testing, and proof-load certification. This makes additive hardware not just a novelty, but a viable, certifiable option for specific rigging applications.
What About Permanent Structures?
Printing full-scale load-bearing structures like beams, lifting lugs, or anchors still pose significant challenges. Strength varies based on print orientation due to how layers are stacked. Microscopic gaps between layers, known as porosity, increase the risk of fracturing under tension or shear. Inspection becomes difficult without destructive testing, and fatigue resistance under repeated stress is still unreliable. Even as process improvements emerge, like using higher-temperature bonding and slower printing speeds, structural use in rigging continues to carry a margin of uncertainty that most operations cannot afford.
Standardization: The Missing Puzzle Piece
Here's where things get interesting: the standards are catching up. ASME’s Y14.46 standard now defines documentation for additive manufacturing, helping designers and inspectors speak the same language. API’s Std 20S sets technical, quality, and qualification standards for 3D printed parts in oil and gas rigging contexts. The IACS recently introduced marine additive manufacturing standards, targeting materials, inspections, and design validation in offshore environments. All these industry bastions have stepped up to help create a world where printed components are not just innovative, but trustworthy and certifiable.
As a supplier that prioritizes code compliance and traceability, we believe any 3D printed rigging gear must meet the same strict documentation and inspection protocols as traditional forged or machined hardware.
Material Science is Driving the Next Leap
Beyond process, material innovation is driving change. Hybrid composites (e.g., dual-fiber polymers) show promise for increased durability without sacrificing customizability. Metallized polymers offer an intriguing middle ground: lighter than full metal, but stronger than raw plastic. DARPA’s new SURGE program aims to qualify each printed part individually, which could rewrite how we approve rigging gear in defense and aerospace contexts.
Where HAS it worked, though?
One of the more high-profile early successes in this space came from Huisman, a heavy equipment manufacturer that used Wire Arc Additive Manufacturing (WAAM) to produce crane hooks capable of lifting up to 350 metric tons. These 3D printed hooks were tested and certified under the supervision of Lloyd’s Register, proving that metal additive components could meet stringent load-bearing standards. While these advancements date back to 2021, they remain a foundational proof of concept for how additive manufacturing can deliver real-world, certifiable performance in custom rigging components.
Where Smart Tech Meets the Hook
3D printing isn't working alone. Alongside it, rigging is being reshaped by other smart technologies. Smart sensors provide real-time stress and load data. RFID makes inspection tracking more reliable. Augmented Reality overlays lift plans and safety warnings in real-time. Together with AM, these tools are making the rigging industry more responsive, traceable, and safer than it’s ever been. As additive manufacturing matures, its presence in rigging will grow in targeted, controlled applications. We’re already seeing traction in custom hooks, lightweight connectors, and specialized fittings for nonstandard lifts. The future viability of printed hardware depends on continued material breakthroughs, stronger standardization, and a shift in how we qualify parts for safety.
3D printing is not set to replace traditional rigging manufacturing anytime soon, but it is becoming a credible option in specific settings. The key is knowing where it adds value without increasing risk. At E-Rigging, we’re watching what's happening closely. Our focus remains on offering gear that’s proven, certifiable, and ready for the field. These advances mark a real shift in rigging and material science. Jobsites are changing fast, and teams adopting the right tech are set up to lead the charge forward.